Methods and apparatus for applying adhesives in patterns to an advancing substrate

ABSTRACT

Aspects of the methods and apparatuses herein involve applying fluids onto an advancing substrate. The apparatuses and methods herein may provide for the application of viscous fluids, such as adhesives, in pre-determined patterns to an advancing substrate. The fluid application apparatus may include a slot die applicator and a substrate carrier. The slot die applicator may include a slot opening, a first lip, and a second lip, the slot opening located between the first lip and the second lip. And the substrate carrier may be adapted to advance the substrate past the slot die applicator as the slot die applicator discharges adhesive onto the substrate. In operation, when a first surface of the substrate is disposed on the substrate carrier, the substrate carrier advances a second surface of the substrate past the slot opening of the slot die applicator.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatuses utilizingcontinuous substrates for manufacturing articles, and more particularly,methods and apparatuses for applying viscous fluid, such as adhesives,to an advancing substrate.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. Webs of material andcomponent parts used to manufacture diapers may include: backsheets,topsheet, absorbent cores, front and/or back ears, fastener components,and various types of elastic webs and components such as leg elastics,barrier leg cuff elastics, and waist elastics. Once the desiredcomponent parts are assembled, the advancing web(s) and component partsare subjected to a final knife cut to separate the web(s) into discretediapers or other absorbent articles. The discrete diapers or absorbentarticles may also then be folded and packaged.

Various methods and apparatuses may be used for attaching differentcomponents to the advancing web and/or otherwise modify the advancingweb. For example, some production operations are configured to applyrelatively high viscosity fluids, such as hot melt adhesives, to anadvancing web. In some instances, the production operations areconfigured to apply hot melt adhesives to an advancing web inpre-determined patterns. These operations may include the use of systemsand methods such as slot die coating, direct gravure, offset gravure andreverse gravure roll coating processes that are extensively described inthe art. However, current systems and methods for applying patternedadhesives to an advancing substrate may have certain limitations.

For example, in the manufacture of absorbent articles such as femininehygiene pads, baby diapers, and adult incontinence pads, the use ofgravure coating processes may be confounded by contamination of theimpression cylinders by fibers separated from the substrates to becoated. Some problems associated with gravure cavities and incompletefluid transfer are described, for example, in U.S. Pat. Nos. 7,611,582B2 and 6,003,513. In some instances, slot die coating may be used forpatterned coating of webs in the manufacture of absorbent products. Theuse of combed shims in slot die transfer processes can provide fineresolution and precise transfer of fluid to the receiving substrate inthe axis transverse to the direction of web travel. Such slot transferprocesses may also be configured with electro-pneumatic switching valvesto intermittently transfer adhesive to an advancing substrate. However,the quality and precision of intermittent transfer of fluids to anadvancing substrate may be limited by the speed of the on/off cycle ofswitching valves used to interrupt the flow of fluid to the slot die ofthe fluid applicator. Thus, as web processing speeds increase, theability of current slot die coating methods to achieve fine resolutionof on/off coat patterns in the direction of web travel decreases.Consequently, it would be beneficial to provide apparatuses and methodsthat apply adhesives and other fluids to a substrate in patterns withrelatively high resolution and high speeds without being limited by thespeed of on/off cycling of switching valves used to interrupt the flowof fluid to the slot die of the fluid applicator.

SUMMARY OF THE INVENTION

Aspects of the methods and apparatuses herein involve applying fluidsonto an advancing substrate. The apparatuses and methods herein mayprovide for the application of viscous fluids, such as adhesives, inpre-determined patterns to an advancing substrate. The fluid applicationapparatus may include a slot die applicator and a substrate carrier. Theslot die applicator may include a slot opening, a first lip, and asecond lip, the slot opening located between the first lip and thesecond lip. And the substrate carrier may be adapted to advance thesubstrate past the slot die applicator as the slot die applicatordischarges adhesive onto the substrate. In operation, when a firstsurface of the substrate is disposed on the substrate carrier, thesubstrate carrier advances a second surface of the substrate past theslot opening of the slot die applicator.

In one form, an apparatus applies a fluid in a pattern to an advancingsubstrate, the substrate having an unconstrained caliper, Hs, and havinga first surface disposed opposite of a second surface. The apparatusincludes: a slot die applicator including a slot opening, a first lip,and a second lip, the slot opening located between the first lip and thesecond lip; a substrate carrier adapted to advance the substrate pastthe slot die applicator, wherein when the first surface of the substrateis disposed on the substrate carrier, the substrate carrier is adaptedto advance the second surface of the substrate past the slot opening ofthe slot die applicator, the substrate carrier comprising: anon-compliant support surface; and a compliant pattern element, whereinthe compliant pattern element includes a pattern surface, and whereinthe compliant pattern element protrudes outward relative to thenon-compliant support surface to define a first minimum distance, R1,between the pattern surface and the non-compliant support surface;wherein the substrate carrier is positioned adjacent the slot dieapplicator to define a minimum distance, Hg, between the pattern surfaceof the pattern element and the first lip and the second lip that is lessthan the unconstrained caliper, Hs, of the substrate; wherein as thesubstrate carrier advances the second surface of the substrate past theslot opening, the compliant pattern element is advanced such that thepattern surface repeatedly advances past the first lip, the slotopening, and the second lip of the slot die applicator; and wherein thepattern surface is deflected away from the slot die applicator as thepattern surface advances along the first lip, the slot opening, and thesecond lip of the slot die applicator to define a second minimumdistance, R2, between the pattern surface and the non-compliant supportsurface, such that R2 is less than R1.

In another form, a method may be used to apply a fluid discharged from aslot die applicator to a substrate in a pattern, the slot die applicatorincluding a slot opening, a first lip, and a second lip, the slotopening located between the first lip and the second lip; and thesubstrate having a first surface disposed opposite of a second surfaceand an unconstrained caliper, Hs. The method includes the steps of:continuously advancing the substrate in a machine direction; engagingthe substrate with a substrate carrier, the substrate carriercomprising: a non-compliant support surface and a pattern element, thepattern element including a pattern surface, wherein pattern elementextends away from the non-compliant support surface to define a firstminimum distance, R1, between the pattern surface and the non-compliantsupport surface; positioning the substrate carrier adjacent the slot dieapplicator to define a minimum distance, Hg, between the pattern surfaceof the pattern element and the first lip and the second lip that is lessthan the unconstrained caliper, Hs, of the substrate; advancing thesecond surface of the substrate past the slot die applicator while thefirst surface of the substrate is disposed on the substrate carrier;intermittently deflecting the pattern surface toward the non-compliantsupport surface such to define a second minimum distance, R2, betweenthe pattern surface and the non-compliant surface, wherein R2 is lessthan R1, by advancing the substrate and the pattern element past thefirst lip, the slot opening, and the second lip of the slot dieapplicator while the first surface of the substrate is disposed on thesubstrate carrier; and discharging fluid from the slot opening of theslot die applicator onto the second surface of the substrate.

In yet another form, an absorbent article includes: a topsheet; abacksheet connected with the topsheet, the backsheet comprising a film;an absorbent core positioned between the topsheet and the backsheet; anda slot coated adhesive positioned on the film, wherein the adhesive isarranged in discrete pattern areas having shapes that correspond withshapes of pattern surfaces on a substrate carrier, the pattern areasseparated by distances, dp, along a machine direction MD thatcorresponds with distances between adjacent pattern surfaces on asubstrate carrier, and wherein each pattern area has a varying thicknessthat defines a cross-sectional profile along the machine direction MD,whereby each pattern area includes a leading end portion and a trailingend portion separated by a central portion, the leading end portiondefining a first thickness, t1, the central portion defining a secondthickness, t2, and the trailing end portion defining a third thickness,t3, and wherein t1 is greater than t2 and t3, and t2 is substantiallyequal to t3.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fluid application apparatus positionedadjacent to an advancing substrate.

FIG. 1A is a side view of a fluid application apparatus depositing fluidonto an advancing substrate in a first example pattern.

FIG. 1B is a side view of a fluid application apparatus depositing fluidonto an advancing substrate in a second example pattern.

FIG. 1C is a side view of a fluid application apparatus depositing fluidonto an advancing substrate in a third example pattern.

FIG. 1D is a side view of a fluid application apparatus depositing fluidonto an advancing substrate in a fourth example pattern.

FIG. 2A is a perspective view of an embodiment of a substrate carrierincluding a pattern roller having a continuous base surface and aplurality of pattern surfaces.

FIG. 2B is a detailed cross-sectional view of the substrate carriershown in FIG. 2A taken along the line 2B-2B.

FIG. 2C is a top side view of a substrate showing a first exampleadhesive pattern thereon.

FIG. 3A is a perspective view of an embodiment of a substrate carrierincluding a pattern roller having a continuous pattern surface andplurality of base surfaces.

FIG. 3B is a detailed cross-sectional view of the substrate carriershown in FIG. 3A taken along the line 3B-3B.

FIG. 3C is a top side view of a substrate showing a second exampleadhesive pattern thereon.

FIG. 4 is a schematic cross-sectional side view of an example substratecarrier.

FIG. 4A1 is a detailed view of the substrate carrier of FIG. 4 includinga compliant pattern element and a compliant base layer connected with abase roll.

FIG. 4A2 is a detailed view of the pattern surface of the patternelement from FIG. 4A1 deflected by a force or forces applied to thepattern surface.

FIG. 4B1 is a detailed view of the substrate carrier of FIG. 4 includinga non-compliant pattern element and a compliant base layer connectedwith a base roll.

FIG. 4B2 is a detailed view of the pattern surface of the patternelement from FIG. 4B1 deflected by a force or forces applied to thepattern surface.

FIG. 4C1 is a detailed view of the substrate carrier of FIG. 4 includinga compliant pattern element connected with a base roll.

FIG. 4C2 is a detailed view of the pattern surface of the patternelement from FIG. 4C1 deflected by a force or forces applied to thepattern surface.

FIG. 5 is a schematic cross-sectional side view of a fluid applicationapparatus.

FIG. 6A is a detailed cross-sectional view of the substrate carrier ofFIG. 5 without the substrate wherein the pattern surface of a patternelement is adjacent a first lip, a second lip, and slot opening of theslot die applicator.

FIG. 6B is a detailed cross-sectional view of a substrate carrier and asubstrate advancing past a slot die applicator and showing the substratebetween a slot opening of the slot die applicator and an advancing basesurface.

FIG. 6C is a detailed cross-sectional view of the substrate carrier andsubstrate of FIG. 6B wherein the base surface is advancing past the slotopening of the slot die applicator such that the substrate is betweenthe slot opening of the slot die applicator and a leading edge of anadvancing pattern surface.

FIG. 6D is a detailed cross-sectional view of the substrate carrier andsubstrate of FIG. 6C wherein the base surface has advanced past the slotopening of the slot die applicator such that the substrate is betweenthe slot opening of the slot die applicator and an advancing patternsurface.

FIG. 6E is a detailed cross-sectional view of the substrate carrier andsubstrate of FIG. 6D wherein the pattern surface has advanced past theslot opening of the slot die applicator.

FIG. 7 is a schematic cross-sectional side view of an embodiment of afluid application apparatus with a substrate carrier including a patternbelt.

FIG. 8 is a schematic cross-sectional side view of another embodiment ofa fluid application apparatus with a substrate carrier including apattern belt.

FIG. 9 is a schematic cross-sectional side view of another embodiment ofa fluid application apparatus with a substrate carrier including apattern belt and a backup plate.

FIG. 10A is a top plan view of a fluid applied in a pattern to asubstrate.

FIG. 10B is a cross sectional view of the substrate and fluid shown inFIG. 10A taken along line 10B-10B.

FIG. 11 is a top plan view of a disposable absorbent article.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. Non-limitingexamples of absorbent articles include diapers, training pants, pull-onpant-type diapers, refastenable diapers or pant-type diapers,incontinence briefs and undergarments, diaper holders and liners,feminine hygiene garments such as panty liners, absorbent inserts, andthe like.

“Diaper” is used herein to refer to an absorbent article generally wornby infants and incontinent persons about the lower torso.

The term “disposable” is used herein to describe absorbent articleswhich generally are not intended to be laundered or otherwise restoredor reused as an absorbent article (e.g., they are intended to bediscarded after a single use and may also be configured to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner).

The term “disposed” is used herein to mean that an element(s) is formed(joined and positioned) in a particular place or position as amacro-unitary structure with other elements or as a separate elementjoined to another element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a layer or layers or fibrousmaterials, films and foils such as plastic films or metallic foils thatmay be used alone or laminated to one or more web, layer, film and/orfoil. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, and the like.Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The terms “elastic” and “elastomeric” as used herein refer to anymaterial that upon application of a biasing force, can stretch to anelongated length of at least about 110% of its relaxed, original length(i.e. can stretch to 10% more than its original length), without ruptureor breakage, and upon release of the applied force, recovers at leastabout 40% of its elongation. For example, a material that has an initiallength of 100 mm can extend at least to 110 mm, and upon removal of theforce would retract to a length of 106 mm (40% recovery). The term“inelastic” refers herein to any material that does not fall within thedefinition of “elastic” above.

The term “extensible” as used herein refers to any material that uponapplication of a biasing force, can stretch to an elongated length of atleast about 110% of its relaxed, original length (i.e. can stretch to10%), without rupture or breakage, and upon release of the appliedforce, shows little recovery, less than about 40% of its elongation.

The terms “activating”, “activation” or “mechanical activation” refer tothe process of making a substrate, or an elastomeric laminate moreextensible than it was prior to the process.

“Live Stretch” includes stretching elastic and bonding the stretchedelastic to a substrate. After bonding, the stretched elastic is releasedcausing it to contract, resulting in a “corrugated” substrate. Thecorrugated substrate can stretch as the corrugated portion is pulled toabout the point that the substrate reaches at least one original flatdimension. However, if the substrate is also elastic, then the substratecan stretch beyond the relaxed length of the substrate prior to bondingwith the elastic. The elastic is stretched at least 25% of its relaxedlength when it is bonded to the substrate.

As used herein, the term “unconstrained caliper” refers to the caliperof the substrate measured according to Edana WSP 120.1 (05), with acircular presser foot having a diameter of 25.40±0.02 mm and an appliedforce of 2.1 N (i.e. a pressure of 4.14±0.21 kPa is applied).

As used herein, the term “compliant” refers to any material with adurometer hardness of 90 or less as measured according to ASTMInternational Designation: D2240-05 (Reapproved 2010) for Type Mdurometers.

As used herein, the term “non-compliant” refers to any material with ahardness value greater than 100 HRBW as defined on the Rockwell B Scalein the American National Standard Designation.

Aspects of the present disclosure involve methods and apparatusesutilizing continuous substrates for manufacturing articles, and moreparticularly, methods and apparatuses for applying fluids onto anadvancing substrate. Particular embodiments of the apparatuses andmethods disclosed herein provide for the application of viscous fluids,such as adhesives, and in some embodiments, the application of adhesivesin pre-determined patterns to an advancing substrate. Embodiments of afluid application apparatus are discussed in more detail below in thecontext of applying adhesives to an advancing substrate having anunconstrained caliper, Hs, and having a first surface disposed oppositeof a second surface. The fluid application apparatus may include a slotdie applicator and a substrate carrier. The slot die applicator mayinclude a slot opening, a first lip, and a second lip, the slot openinglocated between the first lip and the second lip. And the substratecarrier may be adapted to advance the substrate past the slot dieapplicator as the slot die applicator discharges adhesive onto thesubstrate. In operation, when the first surface of the substrate isdisposed on the substrate carrier, the substrate carrier advances thesecond surface of the substrate past the slot opening of the slot dieapplicator. It is to be appreciated that the apparatus and processesdisclosed herein may be used to apply various types of fluids andadhesives in various different patterns to an advancing substrate otherthan those described and depicted herein.

As discussed in more detail below, the substrate carrier may include abase surface and a pattern element. The pattern element includes apattern surface and protrudes outward from the base surface. As such, insubstrate carriers configured with a base surface, the pattern surfaceand the base surface are separated by a distance, Hp. In addition, thesubstrate carrier is positioned adjacent the slot die applicator todefine a minimum distance, Hg, between the pattern surface of thepattern element and the first lip and the second lip that is less thanthe unconstrained caliper, Hs, of the substrate, wherein a sum of thedistance, Hp, and distance, Hg, is greater than the unconstrainedcaliper, Hs, of the substrate. Thus, as the substrate carrier advancesthe second surface of the substrate past the slot opening, the patternelement is advanced such that the pattern surface repeatedly advancespast the first lip, the slot opening, and the second lip of the slot dieapplicator. As discussed below, the pattern element and/or the basesurface of the substrate carrier may be compliant or compressible. Andas such, the pattern element and/or the base surface of the substratecarrier is intermittently compressed as the substrate advances betweenthe slot die applicator and the pattern surface. As such, the patternsurface of the pattern element deflects away from the slot dieapplicator as the substrate and the pattern element advance past thefirst lip, the slot opening, and the second lip of the slot dieapplicator. As the pattern surface is intermittently deflected away fromthe slot die applicator, adhesive discharged from the slot dieapplicator is applied onto the second surface of the advancingsubstrate. More particularly, the adhesive is applied to the substratein an area having a shape that is substantially the same as a shapedefined by the pattern surface.

The apparatuses and methods disclosed herein may include substratecarriers having various configurations. For example, in some embodimentsthe substrate carrier may be configured as a roller. In otherembodiments, the substrate carrier may include an endless belt. Thesubstrate carriers may also utilize various outer surface arrangements.For example, the base surface may be configured as a continuous surfaceand the substrate carrier may include a plurality of discrete patternelements separated from each other by the continuous surface. In such aconfiguration, each pattern element may include a pattern surface andeach pattern element may protrude outward from the continuous surfacesuch that each pattern surface is separated from the continuous surfaceby the distance, Hp. In another example, the pattern surface may beconfigured as a continuous surface and the base surface may include aplurality of discrete base surfaces separated from each other by thepattern element. In such a configuration, the pattern element mayprotrude outward from each of the base surfaces such that each basesurface is separated from the continuous surface by the distance, Hp. Itis to be appreciated that the pattern surface of the pattern element maybe configured in various different shapes and sizes and may beconfigured to define various different patterns. As such, adhesive maybe transferred from the slot die applicator to define various patternson a substrate.

As mentioned above, apparatuses and methods of the present disclosuremay be utilized to apply adhesives to continuous substrates used in themanufacture of absorbent articles. Such substrates may be utilized inabsorbent article components such as, for example: backsheets,topsheets, absorbent cores, front and/or back ears, fastener components,and various types of elastic webs and components such as leg elastics,barrier leg cuff elastics, and waist elastics. Exemplary descriptions ofabsorbent article components and substrates are provided below withreference to FIG. 11. In addition, substrates may include continuouswebs of material and component parts mounted on carrier substrates ormay be in the form of a continuous substrate.

Although much of the present disclosure is provided in the context ofmanufacturing absorbent articles, it is to be appreciated that theapparatuses and methods disclosed herein may be applied to themanufacture of other types of articles and products manufactured fromcontinuous substrates. Examples of other products include absorbentarticles for inanimate surfaces such as consumer products whose primaryfunction is to absorb and retain soils and wastes that may be solid orliquid and which are removed from inanimate surfaces such as floors,objects, furniture and the like. Non-limiting examples of absorbentarticles for inanimate surfaces include dusting sheets, pre-moistenedwipes or pads, pre-moistened cloths, paper towels, dryer sheets anddry-cleaning clothes such. Additional examples of products includeabsorbent articles for animate surfaces whose primary function is toabsorb and contain body exudates and, more specifically, devices whichare placed against or in proximity to the body of the user to absorb andcontain the various exudates discharged from the body. Non-limitingexamples of incontinent absorbent articles include diapers, training andpull-on pants, adult incontinence briefs and undergarments, femininehygiene garments such as panty liners, absorbent inserts, and the like,toilet paper, tissue paper, facial wipes or clothes, and toilet trainingwipes. Still other examples of products may include packaging componentsand substrates and/or containers for laundry detergent and coffee, whichmay be produced in pellets or pouches and may be manufactured in aconverting or web process or even discreet products produced at highspeed such as high-speed bottling lines, cosmetics, razor bladecartridges, and disposable consumer batteries.

FIG. 1 shows a perspective view an embodiment of an apparatus 100 forapplying adhesives to a substrate. The apparatus 100 includes a slot dieapplicator 102 and a substrate carrier 104. As shown in FIG. 1, asubstrate 106 is advancing in a machine direction and is partiallywrapped around the substrate carrier 104. More particularly, thesubstrate 106 includes a first surface 108 disposed opposite a secondsurface 110. And the first surface 108 of the substrate 106 is disposedon an outer surface 112 of the substrate carrier 104 while the secondsurface 110 of the substrate 106 advances past the slot die applicator102. As discussed in more detail below, the second surface 110 of thesubstrate 106 advances past the slot die applicator 102 and adhesive istransferred from the slot die applicator 102 onto the second surface ofthe substrate in a pattern that is substantially the same as a patterndefined on the outer surface 112 of the substrate carrier 104. Asdiscussed in more detail below, the substrate carrier 104 may beconfigured in various ways to deposit fluid 130 discharged from a slotdie applicator 102 onto a substrate 106 in various different patterns,such as shown for example in FIGS. 1A through 1D.

It is to be appreciated that the slot die applicator 102 shown in FIG. 1is a generic representation of a device that is used to apply adhesiveto the substrate 106. The slot die applicator may include a slot opening114, a first lip 116, and a second lip 118. The first lip 116 may alsobe referred to herein as an upstream die lip, and the second lip 118 mayalso be referred to herein as a downstream die lip. The slot opening 114is located between the first lip 116 and the second lip 118. Adhesive orother fluid may be discharged from the slot opening 114 onto the secondsurface 110 of the substrate 106 as the substrate carrier 104 advancesthe substrate past the first lip 116, slot opening 114, and second lip118 of the slot die applicator 102. As discussed in more detail below,the substrate 106 is also intermittently compressed between the slot dieapplicator 102 and substrate carrier 104 as the substrate 106 advancespast the slot die applicator 102. It is to be appreciated that variousforms of slot die applicators may be used herein to apply adhesive orother fluids to an advancing substrate according to methods andapparatuses. For example, U.S. Pat. No. 7,056,386 provides a descriptionof slot die applicators that may be used. Other examples of commerciallyavailable slot die applicators include Nordson Corporation's EP11 Seriesof Slot Die Applicators and ITW Dynatec Gmbh's APEX Series of Slot DieAuto Adhesive Applicators.

Various types of substrate carriers 104 may be used in accordance withthe apparatuses and methods herein. For example, FIGS. 2A and 2B show anembodiment of a substrate carrier 104 configured as a roller 120 adaptedto advance a substrate 106 past the slot die applicator 102. The outersurface 112 of the substrate carrier 104 shown in FIGS. 2A and 2Bincludes a plurality of pattern elements 122 that protrude radiallyoutward from a base surface 124. Each pattern element 122 includes apattern surface 126, and the radial protrusion of the pattern elements122 from the base surface 124 define a distance, Hp, between the patternsurface 126 and the base surface 124. As shown in FIGS. 2A and 2B, thebase surface 124 is configured as a continuous surface 128, and theplurality of discrete pattern elements 122 are separated from each otherby the continuous surface 128. The pattern surfaces 126 in FIGS. 2A and2B define a diamond shape. In some embodiments, the shape and size ofthe pattern surface 126 of each pattern element 122 may be identical orsubstantially identical to each other. It is to be appreciated that thenumber, size, and shape of some or all the pattern surfaces and/orpattern elements may be different. In addition, the distance, Hp,between the base surface 124 and the pattern surface 126 of the patternelement 122 may be the same or different for some or all of the patternelements.

As discussed in more detail below, as the substrate carrier 104 advancesthe substrate 106 past the slot die applicator 102, fluid dischargedfrom the slot die applicator is deposited onto the substrate in apattern substantially matching the shapes of the pattern surfaces on thesubstrate carrier. For example, FIG. 2C shows an example pattern offluid 130 deposited on a second surface 110 of a substrate 106 afterbeing advanced past a slot die applicator while disposed on a substratecarrier having pattern elements 122 and pattern surfaces 126 similar tothose shown in FIGS. 2A and 2B. As shown in FIG. 2C, the fluid 130 isdeposited onto the substrate 106 in discrete pattern areas 132 havingdiamond shapes that correspond with and may mirror the shapes of thepattern surfaces 126 on the substrate carrier 104 shown in FIG. 2A.

FIGS. 3A and 3B show another embodiment of a substrate carrier 104configured as a roller 120 adapted to advance a substrate 106 past theslot die applicator 102. The substrate carrier 104 shown in FIGS. 3A and3B includes a single pattern element 122 including a pattern surface126. And the pattern element 122 protrudes radially outward from aplurality of base surfaces 124. More particularly, the pattern surface126 is configured as a continuous surface 134 and the plurality of basesurfaces are separated from each other by the pattern element 122. Theradial protrusion of the pattern element 122 from the base surfaces 124defines a distance, Hp, between the pattern surface 126 and the basesurfaces 124. The pattern surface 126 in FIGS. 3A and 3B defines acontinuous crossing line pattern wherein the shape and size of each basesurface 124 are identical or substantially identical to each other. Itis to be appreciated that the number, size, and shape of some or all thebase surfaces may be different. In addition, the distance, Hp, betweenthe base surfaces 124 and the pattern surface 126 of the pattern element122 may be the same or different for some or all of the base surfaces.It should also be appreciated that the substrate carrier may beconfigured without base surfaces. For example, the substrate carrier mayinclude a plurality of holes and the pattern surface may be configuredas a continuous surface wherein the plurality of holes are separatedfrom each other by the pattern element.

As previously mentioned, as the substrate carrier 104 advances thesubstrate 106 past the slot die applicator 102, fluid 130 dischargedfrom the slot die applicator 102 is deposited onto the substrate 106 ina pattern substantially matching the shape of the pattern surface 126 onthe substrate carrier 104. For example, FIG. 3C shows an example patternof fluid 130 deposited on a second surface 110 of a substrate 106 afterbeing advanced past a slot die applicator 102 while disposed on asubstrate carrier 104 having a pattern element 122 and pattern surface126 similar to that shown in FIGS. 3A and 3B. As shown in FIG. 3C, thefluid 130 is deposited onto the substrate 106 in a crossing line patterndefining diamond shapes therebetween that correspond with and may mirrorthe shapes of the base surfaces 124 on the substrate carrier 104 shownin FIGS. 3A and 3B.

As previously mentioned, the substrate carrier may be constructed invarious ways such that the base surface and/or pattern elements mayinclude compliant materials. In some configurations, the compliantmaterial(s) may be compressible to allow a pattern surface of a patternelement to deflect away from the slot die applicator. Thus, thesubstrate carrier may be configured such that deflection of the patternsurface away from the slot die applicator compresses the pattern elementand/or base surface as the substrate and the pattern element advancepast the first lip, the slot opening, and the second lip of the slot dieapplicator.

FIG. 4 shows a schematic cross-sectional side view of an examplesubstrate carrier 104 that may be configured with compliant materialsand components that can be compressed and allow the pattern surface 126to deflect in response to a force or forces, F, exerted on the patternsurface 126. The substrate carrier 104 in FIG. 4 is in the form of aroller 120 adapted to rotate around an axis of rotation 105. Inoperation, a force or forces, F, may be exerted on the pattern surface126 as the substrate 106 and the pattern element 122 advance past thefirst lip 116, the slot opening 114, and the second lip 118 of the slotdie applicator 102. It is to be appreciated that the substrate carrier104 may be configured in various ways with various different componentsof compliant materials that allow the pattern surface 126 to deflect.

For example, FIGS. 4A1 and 4A2 show a detailed view of the substratecarrier 104 in the form of a roller 120, such as from FIG. 4, includinga compliant pattern element 122 and a compliant base surface 124connected with a base roll 160 having a non-compliant support surface162. More particularly, the roller 120 in FIGS. 4A1 and 4A2 may includea base layer 164 of compliant material extending radially outward fromthe non-compliant support surface 162 to define the compliant basesurface 124. In some arrangements, the base layer 164 of compliantmaterial may be formed as a cylindrically shaped sleeve or tube 166having an inner radial surface 168 and an outer radial surface 170. Theinner radial surface 168 may surround all or a portion of thenon-compliant support surface 162 of the base roll 160, and the outerradial surface 170 may define all or a portion of the base surface 124.In turn, the pattern element 122 may include a proximal end portion 172and a distal end portion 174 that includes the pattern surface 126,wherein the proximal end portion 172 is connected with outer radialsurface 170 of the base layer 164. As such, the pattern element 122 mayextend radially outward from the base layer 164 of compliant material tothe distal end portion 174. It is to be appreciated that the patternelement 122 may be separately connected with or integrally formed withthe compliant base layer 164. FIG. 4A1 shows the pattern element 122 andbase layer 164 of compliant material in an uncompressed state, whereinthe minimum distance between the pattern surface 126 and thenon-compliant support surface 162 is defined by distance, R1. FIG. 4A2shows the compliant pattern element 122 and compliant base layer 164 ofFIG. 4A1 in a compressed state wherein a force or forces, F, are appliedto the pattern surface 126. Because the pattern element 122 and baselayer 164 are both compliant, the force or forces, F, applied to thepattern surface 126 causes the pattern element 122 and the base layer164 to be compressed against the non-compliant surface 162 of the baseroll 160. The compression of the pattern element 122 and the base layer164 allows the pattern surface 126 to deflect in response to the forces,F. As such, the minimum distance between the pattern surface 126 and thenon-compliant surface 162 is defined as distance, R2, wherein R2 is lessthan R1.

In another example, FIGS. 4B1 and 4B2 show a detailed view of thesubstrate carrier 104 in the form of a roller 120, such as from FIG. 4,including a non-compliant pattern element 122 and a compliant basesurface 124 connected with a base roll 160 having a non-compliantsupport surface 162. More particularly, the roller 120 in FIGS. 4B1 and4B2 may include a base layer 164 of compliant material extendingradially outward from the non-compliant support surface 162 to definethe compliant base surface 124. In some arrangements, the base layer 164of compliant material may be formed as a cylindrically shaped sleeve ortube 166 having an inner radial surface 168 and an outer radial surface170. The inner radial surface 168 may surround all or a portion of thenon-compliant support surface 162 of the base roll 160, and the outerradial surface 170 may define all or a portion of the base surface 124.In turn, the pattern element 122 may include a proximal end portion 172and a distal end portion 174 that includes the pattern surface 126,wherein the proximal end portion 172 is connected with outer radialsurface 170 of the base layer 164. As such, the pattern element 122 mayextend radially outward from the base layer 164 of compliant material tothe distal end portion 174. It is to be appreciated that the patternelement 122 may be separately connected with or integrally formed withthe compliant base layer 164. FIG. 4B1 shows the base layer 164 ofcompliant material in an uncompressed state, wherein the minimumdistance between the pattern surface 126 and the non-compliant supportsurface 162 is defined by distance, R1. FIG. 4B2 shows the compliantbase layer 164 of FIG. 4B1 in a compressed state wherein a force orforces, F, are applied to the pattern surface 126. Because the patternelement 122 is non-compliant and the base layer 164 is compliant, theforce or forces, F, applied to the pattern surface 126 causes thepattern element 122 to push against the base layer 164 such that thebase layer 164 is compressed between the pattern element 122 and thenon-compliant surface 162 of the base roll 160. The compression of thebase layer 164 allows the pattern surface 126 to deflect in response tothe force or forces, F. As such, the minimum distance between thepattern surface 126 and the non-compliant surface 162 is defined asdistance, R2, wherein R2 is less than R1.

In yet another example, FIGS. 4C1 and 4C2 show a detailed view of thesubstrate carrier 104 in the form of a roller 120 from FIG. 4 includinga compliant pattern element 122 connected with a base roll 160. The baseroll 160 includes a non-compliant outer circumferential support surface162 that also defines the base surface 124. In turn, the pattern element122 may include a proximal end portion 172 and a distal end portion 174that includes the pattern surface 126, wherein the proximal end portion172 is connected with non-compliant support surface 162. FIG. 4C1 showsthe pattern element 122 in an uncompressed state, wherein the minimumdistance between the pattern surface 126 and the non-compliant supportsurface 162 is defined by distance, R1. FIG. 4C2 shows the patternelement 122 of FIG. 4C1 in a compressed state wherein a force or forces,F, are applied to the pattern surface 126. Because the pattern element122 is compliant, the force or forces, F, applied to the pattern surface126 causes the pattern element 122 to be compressed against thenon-compliant support surface 162 of the base roll 160. The compressionof the pattern element 122 allows the pattern surface 126 to deflect inresponse to the force or forces, F. As such, the minimum distancebetween the pattern surface 126 and the non-compliant support surface162 is defined as distance, R2, wherein R2 is less than R1. In someinstances, the force or forces, F, may be exerted in a radial directiontoward the axis of rotation 105.

As previously mentioned, the methods and apparatuses herein include asubstrate carrier adapted to advance a substrate past a slot dieapplicator. FIG. 5 shows a schematic cross-sectional side view of anembodiment of a fluid application apparatus 100 including a substratecarrier 104 and a slot die applicator 102. The substrate 106 includes afirst surface 108 and a second surface 110 disposed opposite the firstsurface 108. A portion of the first surface 108 of the substrate 106 isdisposed on the substrate carrier 104, which may be configured as aroller 120 having a plurality of pattern elements 122 protruding from aplurality of base surfaces 124. It is to be appreciated that thesubstrate carrier 104 shown in FIG. 5 may be configured with variousfeatures and aspects of any substrate carriers discussed herein,including those discussed above with reference to FIGS. 1 through 4C2.The roller 120 rotates to advance the second surface 110 of thesubstrate 106 past the slot die applicator 102. A fluid delivery system138 may be used to supply fluid 130, such as an adhesive, to the slotdie applicator 102. It is to be appreciated that the fluid deliverysystem may be configured in various different ways. For example, asshown in FIG. 5, the fluid delivery system 138 may include a pump 140 tomove fluid from a tank 142 to the slot die applicator 102. The fluiddelivery system 138 may also be configured with a pressure relief valve144 configured to help control the pressure of the fluid 130 fed fromthe pump 140. Fluid 130 from the fluid delivery system 138 passesthrough the slot die applicator 102 and slot opening 114 and istransferred to the second surface 110 of the advancing substrate 106.

With continued reference to FIG. 5, fluid 130 passing from the slot dieapplicator 102 is transferred to the second surface 110 of the substrate106 in a pattern or shape that is substantially the same as the patternsurfaces 126 on the substrate carrier 104. As discussed in more detailbelow, the substrate carrier 104 is positioned adjacent the slot dieapplicator 102 to define a minimum distance between the pattern surface126 and slot die applicator 102, which is less than the unconstrainedcaliper of the substrate 106. As such, the pattern element and/or basesurface may be compressed to allow the pattern surface 126 of thepattern element to deflect away from the slot die applicator 102 as thesubstrate 106 and the pattern surface 126 of the pattern element 122advances past the first lip 116, the slot opening 114, and the secondlip 118 of the slot die applicator 102. However, the minimum distancebetween the base surface 124 of the substrate carrier 104 and the slotdie applicator 102 is greater than the unconstrained caliper of thesubstrate 106. As such, the base surface 124 is not compressed as thesubstrate advances past the first lip 116, the slot opening 114, and thesecond lip 118 of the slot die applicator 102. Thus, in operation,although fluid 130 is continuously discharged from the slot dieapplicator 102, fluid 130 is transferred to the advancing substrate 106when the pattern element 122 and/or base surface 124 is compressed aspattern surfaces 126 on the substrate carrier 102 advance past the slotdie opening 114 and deflect the pattern surface 126. And fluid 130 isnot transferred to the advancing substrate 106 when the pattern element122 and/or base surface 124 are uncompressed while the base surfaces 124on the substrate carrier 104 advance past the slot die opening 114. Thefollowing provides a more detailed description of fluid transfer fromthe slot die applicator to the substrate with reference to FIGS. 6Athrough 6E.

FIG. 6A is a detailed cross-sectional view of the substrate carrier ofFIG. 5 shown without the substrate wherein the pattern surface 126 of apattern element 122 is adjacent a first lip 116, a second lip 118, andslot opening 114 of the slot die applicator 102. As shown in FIG. 6A,the substrate carrier 104 includes a non-compliant support surface 162,a base surface 124, and a pattern element 122 protruding from basesurface 124. In an uncompressed state, the pattern element 122 protrudesoutward from the base surface 124 to define a distance, Hp, between thepattern surface 126 and the base surface 124, and to define a minimumdistance, R1, between the pattern surface 126 and the non-compliantsupport surface 162. The substrate carrier 104 is also positionedadjacent the slot die applicator 102 to define a minimum distance, Hg,between the pattern surface 126 of the uncompressed pattern element 122and the first lip 116 and the second lip 118. As discussed below, theminimum distance, Hg, is less than the unconstrained caliper, Hs, of thesubstrate 106 advanced by the substrate carrier 104. In addition, thesubstrate carrier 104 is positioned adjacent the slot die applicator 102to define a minimum distance, Hb, between the base surface 124 and thefirst lip 116 and the second lip 118. As discussed below, the minimumdistance, Hb, may be greater than the unconstrained caliper, Hs, of thesubstrate advanced by the substrate carrier 104.

FIG. 6B is a detailed cross-sectional view of a substrate carrier 104 ofFIG. 6A and a substrate 106 advancing past a slot die applicator 102.The substrate 106 has an unconstrained caliper, Hs, and has a firstsurface 108 disposed opposite of a second surface 110. The first surface108 of the substrate 106 is disposed on the substrate carrier 104. Andthe substrate 106 and substrate carrier 104 are shown as advancingtogether in a machine direction, MD, past the slot die applicator 102.More particularly, the second surface 110 of the substrate 106 isadvancing past a slot opening 114 located between an upstream lip 116and a downstream lip 118 of the slot die applicator 102. As previouslymentioned, the substrate carrier 104 is positioned adjacent the slot dieapplicator 102 to define a minimum distance, Hg, between theuncompressed pattern surface 126 of the pattern element 122 and thefirst lip 116 and the second lip 118 that is less than the unconstrainedcaliper, Hs, of the substrate 106. In addition, the substrate carrier104 is positioned adjacent the slot die applicator 102 to define aminimum distance, Hb, between the base surface 124 and the first lip 116and the second lip 118 that is greater than the unconstrained caliper,Hs, of the substrate. The apparatus 100 may also be configured such thata sum of the distance, Hp, and distance, Hg, is greater than theunconstrained caliper, Hs, of the substrate 106. Thus, a portion 106 aof the substrate 106 that is located between the slot opening 114 of theslot die applicator 102 and the advancing base surface 124 is notpressed against the base surface 124. As such, although fluid 130 iscontinuously discharged from the slot opening 114, fluid 130 is notbeing transferred to the second surface 110 of the substrate 106.

FIG. 6C is a detailed cross-sectional view of the substrate carrier 104and substrate 106 of FIG. 6B wherein the base surface 124 has advancedpast the slot opening 114 of the slot die applicator 102 such that aportion 106 b of the substrate 106 is between the first lip 116 of theslot die applicator 102 and a leading edge 146 of an advancing patternsurface 126. As previously discussed, the minimum distance, Hg, betweenthe pattern surface 126 of the uncompressed pattern element 122 and thefirst lip 116 and the second lip 118 is less than the unconstrainedcaliper, Hs, of the substrate 106. As such, a portion 106 b of substrate106 between the pattern surface 126 and the first lip 116 is pressedagainst and exerts forces on the pattern surface 126. Thus, the patternelement 122 and/or base surface 124 compresses, allowing the patternsurface 126 to deflect away from the first lip 116 to define a minimumdistance, R2, between the pattern surface 126 and the non-compliantsupport surface 162. The fluid 130 being discharged from the slotopening 114 is shown in FIG. 6C as beginning to transfer to the secondsurface 110 of the substrate as the leading edge 146 of the patternsurface 126 and adjacent portion of the substrate 106 begin to advancepast the slot opening 114.

With continued reference to FIG. 6C, the compression of the patternelement 122 and/or base surface 124 allows the pattern surface 126 todeflect away from the first lip 116 to define a compressed distance, Hc,between the pattern surface 126 and the first lip 116. When thesubstrate 106 is made from a material, such as a film, the substrate 106may maintain a caliper that is substantially the same as theunconstrained caliper, Hs, while advancing between the pattern surface126 and the first lip 116. Thus, the pattern surface 126 may deflect bya distance represented by the difference of Hg and Hs, and in someinstances, the distance R2, may be calculated as:R2=R1+Hg−HsIn such a scenario, the compressed distance, Hc, may also be equal to orsubstantially equal to the unconstrained caliper, Hs.

Still referring to FIG. 6C, when the substrate 106 is made from amaterial, such as a nonwoven or laminate including a nonwoven layer, thesubstrate 106 may be compressed to a caliper that is less than theunconstrained caliper, Hs, while advancing between the pattern surface126 and the first lip 116. In such a scenario, the compressed distance,Hc, may be less than the unconstrained caliper, Hs. In other words, thesubstrate 106 may be compressed to a caliper equal to or substantiallyequal the compressed distance, Hc. Thus, the pattern surface 126 maydeflect by a distance represented by the difference of Hg and Hc, and insome instances, the distance R2, may be calculated as:R2=R1+Hg−Hc

FIG. 6D is a detailed cross-sectional view of the substrate carrier 104and substrate of FIG. 6C wherein the base surface 124 and leading edge146 of the pattern surface 126 has advanced past the slot opening 114 ofthe slot die applicator 102 such that the portion 106 b of the advancingsubstrate 106 is between the slot opening 114 of the slot die applicator102 and an advancing pattern surface 126. Because the minimum distance,Hg, between the pattern surface 126 of the uncompressed pattern element122 and the first lip 116 and the second lip 118 is less than theunconstrained caliper, Hs, of the substrate 106, the portion 106 b ofsubstrate 106 between the pattern surface 126 and the first lip 116 andsecond lip 118 of the slot die applicator 102 presses against and exertsforces on the pattern surface 126. As such, the compliant patternelement 122 and/or base surface 124 are compressed, allowing the patternsurface 126 to deflect away from the first lip 116 and second lip 118.As mentioned above, when the substrate 106 is made from a material, suchas a film, the substrate 106 may maintain a caliper that issubstantially the same as the unconstrained caliper, Hs, while advancingbetween the pattern surface 126 and the first lip 116 and second lip118. Thus, the pattern surface 126 may deflect by a distance representedby the difference of Hg and Hs, and in some instances, the distance R2,may be calculated as: R2=R1+Hg−Hs. Also, as mentioned above, when thesubstrate 106 is made from a material, such as a nonwoven or laminateincluding a nonwoven layer, the substrate 106 may be compressed to acaliper that is less than the unconstrained caliper, Hs, while advancingbetween the pattern surface 126 and the first lip 116 and second lip118. Thus, the pattern surface 126 may deflect by a distance representedby the difference of Hg and Hc, and in some instances, the distance R2,may be calculated as: R2=R1+Hg−Hc. The fluid 130 being discharged fromthe slot opening 114 is shown in FIG. 6D as being transferred to thesecond surface 110 of the substrate as the pattern surface 126 andadjacent portion 106 b of the substrate 106 advance past the slotopening 114.

FIG. 6E is a detailed cross-sectional view of the substrate carrier 104and substrate 106 of FIG. 6D wherein the portion 106 b of the substrateand the pattern surface 126 have advanced past the slot opening 114 ofthe slot die applicator 102. As shown in FIG. 6E, an upstream portion126 a of the pattern surface 126 is adjacent the second lip 118, and adownstream portion 126 b of the pattern surface 126 has advanced pastthe second lip 118. As such, the portion 106 b of the advancingsubstrate 106 between the second lip 118 of the slot die applicator 102and the upstream portion 126 a of the advancing pattern surface 126presses against and exerts forces on the pattern surface 126. As such,the compliant pattern element 122 and/or base surface 124 arecompressed, allowing the upstream portion 126 a of the pattern surface126 to deflect away from the first lip 116 and second lip 118 to definethe minimum distance, R2, between the upstream portion 126 a of thepattern surface 126 and the non-compliant support surface 162.

With continued reference to FIG. 6E, the downstream portion 126 b of thepattern surface 126 has advanced past the second lip 118 of the slot dieapplicator 102, and as such, the portion 106 b of the substrate 106 isno longer pressing against downstream portion 126 b of the patternsurface 126, allowing the compliant pattern element 122 and/or basesurface 124 to return to an uncompressed state wherein the downstreamportion 126 b of the pattern surface 126 deflects back away from thenon-compliant surface 162 such that the minimum distance between thenon-compliant surface 162 and the downstream portion 126 b patternsurface 126 is the distance, R1. Once the upstream portion 126 a of thepattern surface 126 has also advanced past the second lip 118, theremainder of the compliant pattern element 122 and/or base surface 124may return to an uncompressed state wherein the both the upstreamportion 126 a and downstream portion 126 b of the pattern surface 126have deflected away from the non-compliant surface 162 such that theminimum distance between the non-compliant surface 162 and the patternsurface 126 is the distance, R1.

Still referring to FIG. 6E, an uncompressed portion 106 c of theadvancing substrate 106 is between the slot opening 114 of the slot dieapplicator 102 and an advancing base surface 124. Because the minimumdistance, Hb, between the base surface 124 and the first lip 116 and thesecond lip 118 that is greater than the unconstrained caliper, Hs, ofthe substrate, a portion 106 c of substrate 106 that advances betweenthe base surface 124, slot opening 114, and the first lip 116 of theslot die applicator 102 is uncompressed. As such, the fluid 130 beingdischarged from the slot opening 114 is shown in FIG. 6E as ceasing tobe transferred to the second surface 110 of the substrate 106 as thebase surface 124 and adjacent uncompressed portion 106 c of thesubstrate advance past the slot opening 114.

As previously mentioned, various forms and configurations of substratecarriers may be used with the presently disclosed methods andapparatuses. For example, FIG. 7 shows a schematic cross-sectional sideview of an embodiment of a fluid application apparatus 100 with asubstrate carrier 104 including an endless pattern belt 148. The patternbelt 148 is wrapped around two rollers 150 adapted to advance patternbelt 148 and substrate past the slot die applicator 102. The patternbelt 148 may include various different combinations, shapes, and typesof pattern elements 122 and base surfaces 124 and/or holes 136 asprevious described. As shown in FIG. 7, the slot die applicator 102 isadjacent the pattern belt 148 at a location where the pattern belt 148is partially wrapped around one of the rollers 150. It is to beappreciated that the slot die applicator 102 may be located adjacentother locations of the pattern belt 148. For example, FIG. 8 shows aschematic cross-sectional side view of an embodiment of a fluidapplication apparatus 100 wherein the slot die applicator 102 isadjacent the pattern belt 148 at a location between the rollers 150. AndFIG. 9 shows a schematic cross-sectional side view of the embodiment ofFIG. 8 with a backup plate 152 located behind the pattern belt 148,wherein the backup plate 148 provides support to the pattern belt 148 tohelp prevent the pattern belt from deflecting away from the slot dieapplicator 102.

With reference to the above description and associated figures, it is tobe appreciated that the apparatuses 100 herein may be used to applyadhesive 130 discharged from a slot die applicator 102 to a substrate106 in a pattern by continuously advancing the substrate in a machinedirection past a first lip 116, second lip 118, and slot opening 114 inthe slot die applicator 102. The substrate 106 may be engaged with asubstrate carrier 104 that may include a base surface 124 and a patternelement 122, wherein the pattern element includes a pattern surface 126.The pattern element 122 protrudes from the base surface 124 to define adistance, Hp, between the pattern surface 126 and the base surface 124.As previously mentioned, in some embodiments, the substrate carrier mayinclude holes 136 instead of or in combination with base surfaces 126adjacent the pattern element 122. The substrate carrier 104 ispositioned adjacent the slot die applicator 102 to define a minimumdistance, Hg, between the pattern surface 126 of the uncompressedpattern element 122 and the first lip 116 and the second lip 118 that isless than the unconstrained caliper, Hs, of the substrate 106. Thesecond surface 110 of the substrate 106 may be advanced past the slotdie applicator 102 while the first surface 108 of the substrate 106 isdisposed on the substrate carrier 104. And the substrate 106 isintermittently compressed between the slot die applicator 102 and thepattern surface 126 of the pattern element 122 by advancing the patternelement as the pattern surface of the pattern element advances past thefirst lip 116, the slot opening 114, and the second lip 118 of the slotdie applicator 102 while the first surface 108 of the substrate 106 isdisposed on the substrate carrier 104.

It is to be appreciated that the methods and apparatuses herein maydeposit fluids, such as adhesives, onto advancing a substrate advancingin a machine direction MD in various designs or patterns. For example,FIG. 10A shows fluid 130 deposited onto the second surface 110 of asubstrate 106 in an example pattern defined by discrete pattern areas132 having varying cross directional CD widths and/or cross directionalCD locations. In addition, because the fluid 130 is deposited onto thesubstrate 106 in pattern areas 132 having shapes that correspond withand may mirror the shapes of the pattern surfaces 126 of the patternelements 122 as discussed above, the fluid 130 may be depositedintermittently to define distances, dp, between pattern areas 132 alongthe machine direction MD that correspond with the distances betweenadjacent pattern surfaces 126 on the substrate carrier 104. In someconfigurations, the fluid 130 may be deposited onto the substrateintermittently to define distances between pattern areas 132 of 30 mm orless along the machine direction of the substrate 106. In addition, thefluid 130 may be deposited on the substrate 106 so as to create avarying thickness that defines a cross-sectional profile along themachine direction MD. For example, FIG. 10B shows a cross-sectional viewof the pattern areas 132 on the substrate 106 of FIG. 10A. As shown inFIG. 10B along the machine direction MD, each pattern area 132 includesa leading end portion 400 and a trailing end portion 402 separated by acentral portion 404. The leading end portion 400 defines a firstthickness, t1, the central portion defines 404 a second thickness, t2,and the trailing end portion 402 define a third thickness, t3. In someconfigurations, the first thickness, t1, is greater than the secondthickness t2, and the third thickness, t3, and the second thickness, t2,may be substantially the same as the third thickness, t3.

As previously mentioned, the apparatuses 100 and methods herein may beused to provide for the application of adhesives in patterns tosubstrates and components during the manufacture of various differentproducts. For the purposes of a specific illustration, FIG. 11 shows oneexample of a disposable absorbent article 250, such as described in U.S.Patent Publication No. US2008/0132865 A1, in the form of a diaper 252that may be constructed from such substrates and components manipulatedduring manufacture according to the apparatuses and methods disclosedherein. In particular, FIG. 11 is a plan view of one embodiment of adiaper 252 including a chassis 254 shown in a flat, unfolded condition,with the portion of the diaper 252 that faces a wearer oriented towardsthe viewer. A portion of the chassis structure is cut-away in FIG. 11 tomore clearly show the construction of and various features that may beincluded in embodiments of the diaper.

As shown in FIG. 11, the diaper 252 includes a chassis 254 having afirst ear 256, a second ear 258, a third ear 260, and a fourth ear 262.To provide a frame of reference for the present discussion, the chassisis shown with a longitudinal axis 264 and a lateral axis 266. Thechassis 254 is shown as having a first waist region 268, a second waistregion 270, and a crotch region 272 disposed intermediate the first andsecond waist regions. The periphery of the diaper is defined by a pairof longitudinally extending side edges 274, 276; a first outer edge 278extending laterally adjacent the first waist region 268; and a secondouter edge 280 extending laterally adjacent the second waist region 270.As shown in FIG. 11, the chassis 254 includes an inner, body-facingsurface 282, and an outer, garment-facing surface 284. A portion of thechassis structure is cut-away in FIG. 11 to more clearly show theconstruction of and various features that may be included in the diaper.As shown in FIG. 11, the chassis 254 of the diaper 252 may include anouter covering layer 286 including a topsheet 288 and a backsheet 290.An absorbent core 292 may be disposed between a portion of the topsheet288 and the backsheet 290. As discussed in more detail below, any one ormore of the regions may be stretchable and may include an elastomericmaterial or laminate as described herein. As such, the diaper 252 may beconfigured to adapt to a specific wearer's anatomy upon application andto maintain coordination with the wearer's anatomy during wear.

The absorbent article may also include an elastic waist feature 202shown in FIG. 11 in the form of a waist band 294 and may provideimproved fit and waste containment. The elastic waist feature 202 may beconfigured to elastically expand and contract to dynamically fit thewearer's waist. The elastic waist feature 202 can be incorporated intothe diaper in accordance with the methods discussed herein and mayextend at least longitudinally outwardly from the absorbent core 292 andgenerally form at least a portion of the first and/or second outer edges278, 280 of the diaper 252. In addition, the elastic waist feature mayextend laterally to include the ears. While the elastic waist feature202 or any constituent elements thereof may comprise one or moreseparate elements affixed to the diaper, the elastic waist feature maybe constructed as an extension of other elements of the diaper, such asthe backsheet 290, the topsheet 288, or both the backsheet and thetopsheet. In addition, the elastic waist feature 202 may be disposed onthe outer, garment-facing surface 284 of the chassis 240; the inner,body-facing surface 282; or between the inner and outer facing surfaces.The elastic waist feature 202 may be constructed in a number ofdifferent configurations including those described in U.S. Pat. No.7,432,413; U.S. Patent Publication No. 2007/0142798; and U.S. PatentPublication No. 2007/0287983; all of which are hereby incorporated byreference herein.

As shown in FIG. 11, the diaper 252 may include leg cuffs 296 that mayprovide improved containment of liquids and other body exudates. Inparticular, elastic gasketing leg cuffs can provide a sealing effectaround the wearer's thighs to prevent leakage. It is to be appreciatedthat when the diaper is worn, the leg cuffs may be placed in contactwith the wearer's thighs, and the extent of that contact and contactpressure may be determined in part by the orientation of diaper on thebody of the wearer. The leg cuffs 296 may be disposed in various ways onthe diaper 202.

The diaper 252 may be provided in the form of a pant-type diaper or mayalternatively be provided with a re-closable fastening system, which mayinclude fastener elements in various locations to help secure the diaperin position on the wearer. For example, fastener elements may be locatedon the first and second ears and may be adapted to releasably connectwith one or more corresponding fastening elements located in the secondwaist region. It is to be appreciated that various types of fasteningelements may be used with the diaper.

Components of the disposable absorbent article (i.e., diaper, disposablepant, adult incontinence article, sanitary napkin, pantiliner, etc.)described in this specification can at least partially be comprised ofbio-sourced content as described in US 2007/0219521A1 Hird et alpublished on Sep. 20, 2007, US 2011/0139658A1 Hird et al published onJun. 16, 2011, US 2011/0139657A1 Hird et al published on Jun. 16, 2011,US 2011/0152812A1 Hird et al published on Jun. 23, 2011, US2011/0139662A1 Hird et al published on Jun. 16, 2011, and US2011/0139659A1 Hird et al published on Jun. 16, 2011. These componentsinclude, but are not limited to, topsheet nonwovens, backsheet films,backsheet nonwovens, side panel nonwovens, barrier leg cuff nonwovens,super absorbent, nonwoven acquisition layers, core wrap nonwovens,adhesives, fastener hooks, and fastener landing zone nonwovens and filmbases.

In at least one exemplary configuration, a disposable absorbent articlecomponent comprises a bio-based content value from about 10% to about100% using ASTM D6866-10, method B, in another embodiment, from about25% to about 75%, and in yet another embodiment, from about 50% to about60% using ASTM D6866-10, method B.

In order to apply the methodology of ASTM D6866-10 to determine thebio-based content of any disposable absorbent article component, arepresentative sample of the disposable absorbent article component mustbe obtained for testing. In at least one embodiment, the disposableabsorbent article component can be ground into particulates less thanabout 20 mesh using known grinding methods (e.g., Wiley® mill), and arepresentative sample of suitable mass taken from the randomly mixedparticles.

In the context of the previous discussion, the apparatuses 100 andmethods herein may be used to provide for the application adhesives inpatterns to substrates and components during the manufacture of anabsorbent article. For example, adhesives may be applied in variouspatterns to portions of any of the topsheet, backsheet films, backsheetnonwovens, absorbent core, core encapsulation webs, acquisition layer,surge layer, secondary topsheet layer, leg cuffs, waist feature, ears,and fastening elements during the manufacture of an absorbent article.In some instances, the adhesive may be a different color than that ofthe substrate. In some applications, the apparatuses and methods hereinmay be adapted to apply adhesives in absorbent core assembly processes,such as described for example in U.S. Patent Publication Nos.US2006/0021695A1; US2006/0048880A1; US2008/0215166A1; andUS2010/0051166A1. In some instances, the apparatuses and methods hereinmay be configured to apply fluid formulations in the form of wetnessindicators, such as disclosed for example in U.S. Patent Publication No.US2011/0137274A1. In yet other instances, the apparatuses and methodsherein may be configured to apply fastening adhesives for feminine carearticles, including sanitary napkins, panty liners, adult incontinencepads, and the like, such as disclosed for example in European PatentPublication No. EP0745368A1.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for applying a fluid discharged from aslot die applicator to a substrate in a pattern, the slot die applicatorincluding a slot opening, a first lip, and a second lip, the slotopening located between the first lip and the second lip; and thesubstrate having a first surface disposed opposite of a second surfaceand an unconstrained caliper, Hs, the method comprising the steps of:continuously advancing the substrate in a machine direction; engagingthe substrate with a substrate carrier, the substrate carriercomprising: a non-compliant support surface and a pattern element, thepattern element including a pattern surface, wherein pattern elementextends away from the non-compliant support surface to define a firstminimum distance, R1, between the pattern surface and the non-compliantsupport surface; positioning the substrate carrier adjacent the slot dieapplicator to define a minimum distance, Hg, between the pattern surfaceof the pattern element and the first lip and the second lip that is lessthan the unconstrained caliper, Hs, of the substrate; advancing thesecond surface of the substrate past the slot die applicator while thefirst surface of the substrate is disposed on the substrate carrier;intermittently deflecting the pattern surface toward the non-compliantsupport surface such to define a second minimum distance, R2, betweenthe pattern surface and the non-compliant surface, wherein R2 is lessthan R1, by advancing the substrate and the pattern element past thefirst lip, the slot opening, and the second lip of the slot dieapplicator while the first surface of the substrate is disposed on thesubstrate carrier; and discharging fluid from the slot opening of theslot die applicator onto the second surface of the substrate.
 2. Themethod of claim 1, wherein the substrate carrier comprises a roller. 3.The method of claim 1, wherein the substrate carrier comprises anendless belt.
 4. The method of claim 1, wherein the substrate carrierfurther comprises a compliant base surface, wherein the pattern elementprotrudes from the compliant base surface to define a distance, Hp,between the pattern surface and the compliant base surface.
 5. Themethod of claim 4, wherein the substrate carrier is positioned adjacentthe slot die applicator to define a minimum distance, Hg, between thepattern surface of the pattern element and the first lip and the secondlip that is less than the unconstrained caliper, Hs, of the substrate;and wherein a sum of the distance, Hp, and distance, Hg, is greater thanthe unconstrained caliper, Hs, of the substrate.
 6. The method of claim1, wherein the fluid comprises an adhesive.
 7. The method of claim 1,wherein the fluid is a different color than the substrate.